2005 MITSUBISHI 380 Gauge

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONING AND VENTILATION55-143
PERFORMANCE TEST M1552001400526
The vehicles to be tested should be parked out of direct sun-
light.
1. Close the high and low-pressure valve of the gauge
manifold.
2. Connect the charging hose (blue) to the low-pressure valve
and connect the charging hose (red) to the high-pressure
valve of the gauge manifold.
3. Install the quick joint (for low-pressure) to the charging hose
(blue), and connect the quick joint (for high-pressure) to the
charging hose (red).
To connect the quick joint, press section A firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the hose.
4. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick joint (for
high-pressure) to the high-pressure service valve.
NOTE: The high-pressure service valve is on the A/C pipe
and the low-pressure service valve is on the suction hose.
5. Start the engine.
6. Set the A/C controls as follows:
A/C switch: A/C ON position
Mode selection: FACE position
Temperature control: MAXIMUM COOLING position
Air selection: RECIRCULATION position
Blower switch: Maximum air volume
7. Adjust engine speed to 1,500 r/min with A/C clutch engaged.
8. Engine should be warmed up with doors and windows
closed.
9. Insert a thermometer in the center air outlet and operate the
engine for 20 minutes.
NOTE: If the A/C clutch cycles, take the reading before the
clutch disengages.
10.Note the discharge air temperature.
PERFORMANCE TEMPERATURE CHART
GARAGE AMBIENT AIR TEMPERATURE C
(
F)20 (68) 25 (77) 30 (86) 35 (95)
Discharge air temperature
C (F) 1 (34) 6 (43)
Compressor high pressure kPa (psi) 1275 (185)
1863 (270)
Compressor low pressure kPa (psi) 49 (7.1)
294 (42.7)

ENGINE COOLING DIAGNOSIS
ENGINE COOLING14-4
INSPECTION PROCEDURE 2: Engine Overheating
DIAGNOSIS
STEP 1. Remove the radiator cap and check for coolant
contamination.
Q: Is the coolant contaminated with rust and oil?
YES : Replace it. Refer to P.14-27.
NO : There is no action to be taken. Go to Step 2.
STEP 2. Check the radiator cap valve opening pressure.
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93
123 kPa (14 18 psi)
Q: Does the reading remain at or above the minimum limit?
YES : Go to Step 3.
NO : Replace the radiator cap. Then go to Step 5.
STEP 3. Check thermostat operation.
Refer to 38.
Q: Does the thermostat operate correctly?
YES : Go to Step 4.
NO : Replace the thermostat, then go to Step 5.
STEP 4. Check the drive belt for slippage or damage.
Refer to GROUP 00, Maintenance Service
Drive Belts
(Check Condition). <3.8L Engine>39 .
Q: Is the drive belt loose or damaged?
YES : Adjust or replace the drive belt, then go to Step 5.
NO : There is no action to be taken.
STEP 5. Retest the system.
Check the engine coolant temperature.
Q: Is the engine coolant temperature abnormally high?
YES : Return to Step 2.
NO : The procedure is complete.

ON-VEHICLE SERVICE
ENGINE COOLING14-27
RADIATOR CAP PRESSURE CHECKM1141001300419
NOTE: Be sure that the cap is clean before testing. Rust or
other foreign material on the cap seal will cause an improper
reading.
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops
moving.
Minimum limit: 83 kPa (12 psi)
Standard value: 93
123 kPa (14 18 psi)
3. Replace the radiator cap if the reading does not remain at or
above the limit.
ENGINE COOLANT REPLACEMENTM1141001200478
When removing the radiator cap, use care to avoid
contact with hot coolant or steam. Place a shop towel
over the cap and turn the cap counterclockwise a lit-
tle to let the pressure escape through the vinyl tube.
After relieving the steam pressure, remove the cap by
slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and engine
after unplugging the radiator drain plug and removing the
radiator cap.

INTAKE MANIFOLD
INTAKE AND EXHAUST15-9
>>C<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
Be careful not to allow any engine oil to enter the fuel
rail.
Be careful not to bend the fuel high-pressure hose as it
is made of plastics.
1. When connecting the fuel high-pressure hose to the fuel rail,
apply a small amount of new engine oil to the O-ring and
then insert the fuel high-pressure hose, being careful not to
damage the O-ring.
2. While turning the fuel high-pressure hose to the left and
right, install it to the fuel rail.
3. Check that the injector turns smoothly. If it does not turn
smoothly, the O-ring may be trapped. Remove the fuel
high-pressure hose and then re-insert it into the fuel rail and
check again.
INSPECTIONM1151003100672
Check the following points; replace the part if a problem is
found.
.
Intake Manifold Check
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port.
3. Using a straight edge and feeler gauge, check for distortion
of the cylinder head installation surface.
Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-13
>>B<< LEFT BANK HEATED OXYGEN SENSOR
(REAR) INSTALLATION
Use special tool MB991953 to install the heated oxygen sensor.
INSPECTIONM1151003400587
Check the following points; replace the part if a problem is
found.
.
Exhaust Manifold Check
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm (0.006 inch) or less
Limit: 0.20 mm (0.008 inch)

STARTING SYSTEM
ENGINE ELECTRICAL16-24
REMOVAL SERVICE POINT
.
<> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from under the vehicle.
INSPECTIONM1162001100197.
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
2. Connect a 12-volt battery between the S-terminal and
M-terminal.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
4. Check the pinion-to-stopper clearance (pinion gap) with a
feeler gauge.
Standard value: 0.5
2.0 mm (0.02 0.07 inch)
5. If the pinion gap is out of specification, adjust by adding or
removing gasket(s) between the magnetic switch and front
bracket.
.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
This test must be performed quickly (in less than 10 sec-
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and
M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't,
replace the magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-28
INSPECTIONM1162001300102.
COMMUTATOR CHECK
1. Place the armature on a pair of V-blocks, and check the
deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.004 inch)
2. Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)
3. Check the depth of the undercut between segments.
Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.008 inch)
.
BRUSH CHECK
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length. Replace the
brush holder if this measurement exceeds the limit.
Minimum limit:
7.0 mm (0.28 inch)
2. If the contacting surface has been corrected or the brush
has been replaced, correct the contacting surface by
winding sandpaper around the commutator.
.

BASIC BRAKE SYSTEM DIAGNOSIS
BASIC BRAKE SYSTEM35A-10
STEP 7. Check the wheel bearings for end play.
(1) Remove the brake discs.
(2) Place a dial gauge as shown, and measure the end play
while moving the hub in the axial direction.
Limit: 0.05 mm (0.002 inch)
Q: Does the measured end play exceed the limit?
YES : Replace the faulty hub assembly. Then go to Step 10.
NO : Go to Step 8.
STEP 8. Check whether the brake booster or master
cylinder return is insufficient.
Q: Is the brake booster or master cylinder return
insufficient?
YES : Replace the part. Then go to Step 10.
NO : Go to Step 9.
STEP 9. Adjust the brake pedal or brake booster pushrod.
Refer to P.35A-13 or P.35A-26.
Q: Are the brake pedal and the brake booster pushrod
adjusted correctly?
YES : Go to Step 10.
NO : Adjust the brake pedal or the brake booster pushrod.
Then go to Step 10.
STEP 10. Recheck symptom.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at step 1. If a new symptom surfaces, refer
to the symptom chart.